Thermoplastic-Layered Rubber Hose Shaping With Integrated Insulation
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Solution Overview
Problem
Conventional methods for manufacturing rubber hoses with thermal insulation are inefficient, laborious, and prone to environmental fluid ingress due to the need for a separate insulation layer, which often fails to achieve intimate contact and is susceptible to damage.
Innovation Solution
A method involving surrounding a cured rubber hose with a thermoplastic layer to mold it into a desired shape, providing thermal insulation and retaining the hose in a second shape different from its initial form, while maintaining the cross-sectional shape and allowing for bends below the minimum recommended radius.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate external insulation layer is used to thermally insulate the rubber hose, then thermal insulation is provided, but the process becomes inefficient, laborious, and time-consuming
Solution Approach 1:
The patent combines the insulation layer and the protective outer layer into a single integrated thermoplastic layer that performs both functions simultaneously, eliminating the need for separate insulation and protective layers, thus streamlining the manufacturing process and improving productivity
Solution Approach 2:
The thermoplastic layer serves multiple functions: it provides thermal insulation, acts as a protective barrier against environmental fluids, and maintains hose shape during bending, replacing what would traditionally require multiple separate components
2Temperature
If a separate external insulation layer is used, then thermal insulation is achieved, but intimate contact with the hose is not achieved and the hose remains exposed to environmental fluids
Solution Approach 1:
The patent merges the insulation function and protective barrier function into a single thermoplastic layer that is extruded directly over the hose, ensuring intimate contact and continuous protection without gaps or exposure points
Solution Approach 2:
The thermoplastic layer combines insulating properties with protective characteristics, creating a composite structure that simultaneously provides thermal insulation and acts as a barrier against environmental fluid ingress
3Adaptability or versatility
If the rubber hose is bent to achieve desired shapes, then installation flexibility is improved, but the hose may be damaged or kinked
Solution Approach 1:
The thermoplastic layer changes its physical parameters during the molding process, becoming pliable at elevated temperatures to allow bending into complex shapes, then solidifying upon cooling to lock in the desired configuration and protect the hose during service
4Adaptability or versatility
If multiple separate layers (hose, insulation, protective layer) are used, then functional requirements are met, but the device complexity increases
Solution Approach 1:
The patent consolidates what would traditionally be separate insulation and protective layers into a single thermoplastic layer, reducing the total number of components and simplifying the overall structure while maintaining all necessary functions
Solution Approach 2:
The single thermoplastic layer is designed to perform multiple functions simultaneously: thermal insulation, environmental fluid barrier, and shape retention, replacing what would require multiple specialized layers
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method efficiently integrates thermal insulation and maintains hose shape and functionality, preventing environmental fluid ingress and reducing the risk of damage, while enabling bends below the minimum recommended radius without kinking.
Implementation Method 1
molding the cured rubber hose surrounded with the thermoplastic layer at a molding temperature
Implementation Method 2
The outer thermoplastic layer may also provide thermal insulation for the rubber hose
Data Source
AI summary
A method of manufacturing a tube assembly includes surrounding an outer surface of a cured rubber hose with a thermoplastic layer, the cured rubber hose extending along a length between a first end and a second end and having a first shape along its length, the thermoplastic layer surrounding the cured rubber hose along at least a portion of the length. The cured rubber hose surrounded with the thermoplastic layer is molded into a second shape different than the first shape. The cured rubber hose is retained in the second shape by the thermoplastic layer. A tube assembly includes a cured rubber hose and thermoplastic layer surrounding the rubber hose along at least a portion of the length of the cured rubber hose. The cured rubber hose has been cured in a first shape along its length and the thermoplastic layer retains the cured rubber hose in a second shape.